Professional Documents
Culture Documents
Austin Bonnett
EASA Education and Technology Consultant Gallatin, MO
Introduction
Stator design can not be discussed in a vacuum because it is inseparably connected to the rotor through mutual inductance. Another critical component is the motor enclosure which houses the stator and rotor and facilitates the critical cooling circuit.
Equivalent Circuit
1. Efficiency vs. Power Factor 2. Current-Torque Characteristics 3. Noise vs. Efficiency 4. Size vs. Operating Temperature 5. Insulation Quality vs Operating Temperature 6. Cost vs. Performance 7. Reliability vs. Enclosure
1. Power and Speed Ratings 2. Power Source 3. Enclosure and Frame Selection 4. Speed-Torque Issues 5. Duty Cycle 6. Environmental Factors
Power engineers from all aspects of industry can benefit from a basic understanding of the following items. 1. Motor Nomenclatures 2. The Motor as a Converter of Energy 3. Power Equations 4. Efficiency and Loss Management 5. The MMF Forces 6. Using Simple Design Ratios 7. Containment of Motor Forces and Stresses
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Stator Stresses
Thremal stresses
Thermal aging Voltage variation Cycling Loading Ventilation Ambient
Mechanical stresses
Coil movement Rotor strikes Defective rotor Flying objects Lugging of leads
Environmental stresses
Moisture Chemical Abrasion Damaged parts Excessive ambient Restricted ventilation
Electrical stresses
Dielectric aging Tracking Corona Transients
Residual
Stress concentrations Uneven bar stresses
Dynamic
Vibration Rotor rub Overspeeding Cyclic stresses Centrifugal force
Magnetic
Rotor pullover Noise Vibration Off magnetic center Saturation of lamintations Circulating currents
Environmental
Contamination Abrasion Foreign particles Excessive ambient Restricted ventilation
Other
Misapplications Poor design practices Manufacturing variation Loose bars, core Transient torques Wring direction of rotation
Temp. vs. Life Curves for Insulation Systems by AIEE 510 Method
Ring Laminations
Segmented Laminations
SURFACE INSULATION
Oxidation Core Plate
ANNEALING
Simple Stress Relief Stress Relief Plus Decarburization (Grain Growth)
STEEL LOSSES
Core Loss (1.6 w/# - 3.1 w/# Range) Hysteresis Loss Eddy Current Loss
Leakage Flux
E n P m 105 Bg = 13.95 f T N1 Di Lg Kp Kd
KILOLINES INCHES2
Form-Wound Stator
Stator Winding
4. Winding Elements
Types of windings
Random-wound lap Random-wound concentric Form-wound
Coils
Random wound Form wound
Slot insulation
Slot liner Bottom sticks Center sticks Topsticks Groundwall
Types of varnish
Polyester 100% solid epoxy or 100% polyester
Magnet wire
Round Rectangular
4. Winding Elements-cont.
Group insulation
Phase paper Sleeving Center sticks
Coil bracing
Tie cord Dacron felt Surge rope Tape
Connection
Lead cable Sleeving Tie cord
Treatment
Vacuum pressure impregnation Dip varnish Abrasion-resistant coating
Random wound
Form wound
FORM-WOUND STATOR
Slot insulation should protrude at least 3/8 beyond the end of the slot.
Phase Insulation
Two examples of alternative bracing on a random winding (left) and a form winding (right). These examples use epoxy to simulate a surge.
Stator/Rotor Cooling
Air Ducts
Rotor Forces
The majority of rotor failures are caused by a combination of various stresses which act on the rotor. In general terms, these stresses can be broken down as follows: Thermal Residual Environmental Electromagnetic Dynamic Mechanical
Calculating Slip
A. Semi-processed, no insulation B. Fully processed, core plate insulation C. Semi-processed and annealed
A. B. C. D.
Aluminum with hard anodize Aluminum without insulation Aluminum with light anodize Copper without insulation
Typical Lamination
Stator Shaft Air Gap
Rotor
Typical lamination set showing relationship between stator and rotor teeth and air gap.
Fabricated Rotors
Side view of a large cast rotor showing the position of the air ducts.
Air Gap
This photo illustrates the air gap between the stator inside diameter and the rotor outside diameter.
Skewing
Skew is the angular twist of a slot away from the axial direction. Typical skew is one stator slot pitch. The purpose of the skew is to reduce special harmonics in the air gap flux that are introduced by a finite number of slots and the slotting combination. The results of skewing are: Reduction of induced E.M.F. in the rotor bar. Decrease in rotor leakage reactance. A non-uniform axial distribution of the air gap flux. Skewed bars have a current that has a circumferential component which develops a small axial force which imposes an additional load on bearings. Non-uniform air gap flux increases core and stray losses. Improved speed-torque characteristics, including elimination of locking torque at zero speed and cusps at various speeds. Reduced likelihood of noise problems.
Before swaging
After swaging
7. Motor Noise & Vibration As Influenced by the Stator and Rotor Design
Ventilation Noise
Ventilation (windage) noise is created in the air stream used to cool the motor. Windage noise is generated by the air flowing in and around the motor, as follows: 1. Fan blades rotating in close proximity to mounting bolts or other mechanical parts. 2. Restrictions in the air stream. 3. Abrupt changes in the direction of air flow. 4. Rotor air duct vent spacers passing by stationary stator vent spacers. Generally, the predominant noise source for six-pole and faster motors (two- through eight-pole speeds for TEFC motors) is ventilation noise. This is due to the higher fan speeds and greater CFM. Thus, to reduce noise levels on two- through six-pole motors, the ventilation noise must be reduced.
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